ES2649173T3 - Hydraulic embossing of a double-sided nonwoven fibrous veil - Google Patents

Abstract

A double-sided fibrous, nonwoven material comprising a first set of hydraulically punctured fibers with a veil of a second set of fibers, the first set of fibers containing mainly short fibers having a length of 0.7 mm to 25 mm and the second set of fibers containing mainly one of (a) substantially continuous filaments, and (b) short fibers having an average fiber length of at least twice the average fiber length of the first set of fibers, the material having a first surface predominantly comprising the first set of fibers and a second opposed surface comprising predominantly the second set of fibers, the first surface being embossed in reflective form to have a visual and tactile appearance depending on a support embossing in which it is made embossing

Description

DESCRIPTION

Hydraulic embossing of a double-sided nonwoven fibrous veil Field of the invention

The present invention relates to an embossed nonwoven material and the nonwoven veil embossing method. 5 Especially, the present invention relates to fibrous and double-face embossed nonwoven materials, and their manufacture.

Background of the invention

It is known to use high pressure jets to interlace fibers in a nonwoven web, sometimes called hydro-entanglement, hydraulic punching or yarn entanglement. Typically, these processes 10 are used with carded nonwoven veils, although there is some hydraulic punching of wet nonwoven veils and nonwoven veils by nonwoven filament bonding. These processes support the nonwoven web on a highly porous element, such as a mesh belt or a metal sieve so that the fluid can pass at high pressure through the nonwoven web and continue through the porous element to be collected. A negative pressure (vacuum) is typically applied to the porous element to help extract fluid from the nonwoven web through the support element.

It is known how to produce an embossed nonwoven fabric that has interwoven nonwoven fibers. US Patent No. 4,718,152 refers to a method for the production of embossed nonwoven fabric in which a fibrous veil is subjected to high energy treatment with high velocity water currents not only to interlace the fiber, but also to emboss the fibrous veil. This last process is sometimes referred to as hydrographic. The fiber entanglement treatment is performed on a plurality of non-porous supports arranged in a multi-stage manner at regular intervals along the path of the fibrous web. The embossing treatment is carried out on a separate non-porous support arranged below the non-porous supports on which the entanglement of the fiber takes place. For the precursor veils described in this patent, both sides of the veil are the same.

25 It would be useful to provide an improved embossed nonwoven material and an efficient method for its production. In particular, it would be useful to provide double-sided nonwoven fabrics that are often preferred as cleaning substrates.

WO 2004/063451 and US 2006/191115 disclose double-sided fibrous nonwoven materials, which have been hydraulically punched using suction.

Summary

An objective of the present invention is to develop a double-face embossed fibrous nonwoven material in reflective form.

A further object of the present invention is to provide a cleaning substrate comprising the nonwoven material of claim 1.

In general, unless explicitly stated otherwise, the materials and processes described may alternatively be formulated so that they comprise, consist of, or consist essentially of, any of the appropriate components, structural units or stages disclosed herein. The materials and processes described may additionally, or alternatively, be formulated to be devoid, or substantially free, of any of the components, materials, ingredients, adjuvants, structural units, species and stages used in the state of the art compositions or not 40 are necessary for the achievement of the function and / or the purpose of this description.

Definitions:

Two-component fiber - A fiber that has been formed by extrusion of polymer sources from separate extruders and spun together to form a single fiber. Typically, two separate polymers are extruded, although a two-component fiber may encompass the extrusion of the same polymeric material from separate extruders. The extruded polymers are arranged in different areas positioned substantially constant through the cross-section of the two component fibers and extend substantially continuously along the length of the two component fibers. The configuration of the two-component fibers can be symmetric (for example, envelope: core or side: side) or it can be asymmetric (for example, the core misaligned within the sheath; crescent moon configuration within a fiber having 50 a general round shape). The two sources of polymers can be present in proportions of, for example

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(but not exclusively), 75/25, 50/50 or 25/75.

Two constituent fiber - A fiber that has been formed from a mixture of two or more extruded polymers from the same spinning nozzle. The fibers of two constituents do not have the different polymeric components arranged in distinct zones in a relatively constant manner across the cross-sectional area of the fiber and the different polymers are generally not continuous along the entire length of the fiber, usually forming instead fibrils that begin and end randomly. The fibers of two constituents are sometimes also referred to as fibers of multiple constituents.

Binder - An adhesive material used to bond a veil of fibers together or join a veil with another. The main properties of a binder are adhesion and cohesion. The binder may be in solid form, for example a powder, film or fiber, in liquid form, for example a solution, dispersion or emulsion or in the form of foam.

Calendering - the process of smoothing the surface of paper, non-woven material or textile sheet by pressing it between opposite surfaces. Opposite surfaces include flat plates and rollers. One or both of the opposite surfaces can be heated.

Cardadora - A machine designed to separate individual fibers from a mass of fibers, to align the fibers and deliver the aligned fibers like a wadding or veil. The fibers in the veil can be aligned randomly or parallel to each other predominantly in the machine direction. The card consists of a series of rollers and drums that are covered with a plurality of projecting wires or metal teeth.

Carded Veil - A non-woven veil of carded fibers.

Carding - A process for manufacturing nonwoven veils in a carding machine.

Cellulose fiber - A fiber composed substantially of cellulose. Cellulosic fibers come from artificial sources (for example, regenerated cellulose fibers or liocel fibers) or from natural sources such as cellulose fibers or cellulose pulp from woody and non-woody plants. Woody plants include, for example, deciduous trees and conifers. Non-woody plants include, for example, cotton, flax, esparto, kenaf, sisal, abaca, milkweed, straw, jute, hemp and bagasse.

Cellulose material - A material composed substantially of cellulose. The material can be a fiber or a film. Cellulosic materials come from artificial sources (for example, films and fibers of regenerated cellulose) or from natural sources such as fibers or pulp of woody and non-woody plants.

Conjugated fiber - Fiber that has been formed by extrusion of polymer sources from separate extruders and spun together to form a single fiber. A conjugate fiber encompasses the use of two or more separate polymers, each supplied by a separate extruder. The extruded polymers are arranged in different areas positioned substantially constant across the cross section of the conjugate fiber and extend substantially continuously along the length of the conjugated fiber. The form of the conjugated fiber may be any form that is convenient for the producer for the intended end use, for example, round, trilobed, triangular, dog bone, flat or hollow.

Machine transverse direction (CD) - The direction perpendicular to the machine direction.

Cut fiber - A fiber that has been formed in, or cut to a length. The cut fibers include, for example, direct access fibers and cut fibers.

Denier - A unit used to indicate the fineness of a filament given by the weight in grams of 9,000 meters of filament. A filament of 1 denier has a mass of 1 gram per 9,000 meters in length.

Fiber - A form of material characterized by an extremely high ratio of length to the diameter. As used herein, the terms fiber and filament are used interchangeably unless specifically indicated otherwise.

Long fiber - A fiber that has an average length of at least 25 mm and up to approximately 200 mm or more. A type of long fibers, referred to as 'cut fibers', are usually made as a veil by carding.

Liocel - Artificial cellulose material obtained by the direct dissolution of cellulose in an organic solvent without the formation of an intermediate compound and the subsequent extrusion of the cellulose solution and the organic solvent in a coagulation bath.

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Machine Direction (MD) - The direction of displacement of the surface that is formed on which the fibers are deposited during the formation of a nonwoven web material.

Blown fibers in the molten state - A fiber formed by extrusion of a molten thermoplastic material as filaments from a plurality of thin, normally circular capillaries, punched in a high velocity gas stream (eg, air) that attenuates the filaments of molten thermoplastic material to reduce its diameter. After that, the meltblown fibers are transported by the high velocity gas stream and are deposited on a collecting surface to form a veil of meltblown fibers dispersed at random. The process of blowing in the molten state includes the process of spraying in the molten state. The meltblown fibers may be short fibers, long fibers, or substantially continuous filaments.

Non-thermoplastic polymer - Any polymeric material that does not fall within the definition of thermoplastic polymer.

Textile, laminate or non-woven veil - A material that has a structure of individual fibers that are interwoven, but not in an identifiable manner as in a knitted or knitted textile. Nonwoven materials have been formed from many processes such as, for example, melt-blowing, spinning, carding, air-laying and water-laying processes. The basis weight of nonwoven materials is normally expressed in weight per unit area, for example, in grams per square meter (gmc or g / m2) or ounces per square yard (1 oyc = 33.9 gmc). As used herein, a non-woven sheet includes a sheet of paper laid in wet.

Polymer - A long chain of repetition of structural units. It generally includes, for example, homopollmeros, copollmeros, such as, for example, block, graft, random and alternating copollmeros, terpollmeros, etc., and mixtures and modifications thereof. In addition, unless specifically limited, the term "polymer" includes all possible geometric configurations. These configurations include, for example, isotactic, syndiotactic and random symmetries.

Embossed nonwoven material in reflective form - An embossed nonwoven material made by a process in which a stream of fluid such as water is fired on a nonwoven material, strikes a support for the nonwoven material, and is reflected outside the Support back to non-woven material.

Regenerated cellulose - Artificial cellulose obtained by chemical treatment of natural cellulose to form a soluble chemical derivative or intermediate compound and subsequent decomposition of the derivative to regenerate cellulose. Regenerated cellulose includes spun rayon and cellophane film. The regenerated cellulose processes include the viscose process, the cuprammonium process and the saponification of cellulose acetate.

Short fiber - A fiber that has been formed in, or cut to, a length of 0.7 mm to 25 mm. It is noted that naturally occurring fibers, such as cellulose, generally do not require cutting since they are formed to a suitable length. The short fibers can be applied by wet forming techniques or by air laying.

Direct access fiber - A fiber that has been formed into, or cut up to, lengths generally from one millimeter to thirteen millimeters. It is observed that naturally occurring fibers, such as cellulose, generally do not require cutting since they are formed of a suitable length.

Non-woven double-sided material - A sheet of non-woven material that has different fiber compositions and / or different average fiber lengths on its two opposite surfaces.

Yarn entanglement - A method of joining a nonwoven web carded by entangling the fibers of that veil around adjacent fibers using a plurality of high pressure fluid streams. The fluid can be water. The non-woven veil is supported on a porous belt or sieve to allow fluid to pass through it. A negative pressure (vacuum) is applied to the side of the belt opposite the nonwoven veil to extract water from the veil through the belt.

Spinning filament filament - A filament formed by extrusion of molten thermoplastic materials from a plurality of thin, normally circular capillaries, of a spinning nozzle. The diameter of the extruded filaments is then reduced rapidly, for example, by reductive extraction and / or other well-known mechanisms of nonwoven filament bonding. Spinned fibers that are nonwoven filament joints are generally substantially continuous with deniers within the range of about 0.1 to 5 or more.

Nonwoven veil by nonwoven filament bonding - Veils formed (usually) in a single process by extrusion of at least one molten thermoplastic material as filaments from a plurality of fine, normally circular capillaries, of a spinneret nozzle. The filaments are partially cooled and then removed

to reduce the denier of the fiber and increase the molecular orientation within the fiber. The filaments are generally continuous and not sticky when deposited on a collection surface such as a fibrous block. Then the spindled fibrous wadding is attached.

Cut fiber - A fiber that has been formed into, or cut up to, lengths cut from generally 5 inches to eight inches (25 mm to 51 mm).

Synthetic fiber - A fiber composed of artificial material, for example, glass, polymer, combination of polymers, metals, carbon, regenerated cellulose or liocel.

Substantially continuous - With reference to the polymeric filaments of a nonwoven web, it is understood that most of the filaments or fibers formed by extrusion through holes remain as continuous uncut filaments 10 as extracted and collected on a mobile belt or other device Some filaments may break during the attenuation or extraction process, the substantial majority of the remaining filaments remaining continuous.

Tex - A unit used to indicate the fineness of a filament given by the weight in grams of 1,000 meters of filament. A filament of 1 tex has a mass of 1 gram per 1,000 meters in length.

15 Thermoplastic polymer - A polymer that can melt, soften when exposed to heat and generally return to its non-softened state when cooled to room temperature. Thermoplastic materials include, for example, polyvinyl chlorides, some polyester, polyamides, polyfluorocarbons, polyolefins, some polyurethanes, polystyrenes, polyvinyl alcohol, copolymers of ethylene and at least one vinyl monomer (for example, poly (vinyl ethylene acetates) , and acrylic resins.

20 Thermosetting polymer - A polymer that permanently hardens when heated and / or crosslinked.

Brief description of the drawings:

Referring now to the drawings in which similar elements are numbered the same in the various figures:

FIG. 1 is a schematic illustration of a preferred embodiment of an embossing apparatus.

FIG. 2 is a schematic illustration of another preferred embodiment of an embossing apparatus.

25 FIG. 3 is a schematic illustration of yet another preferred embodiment of an embossing apparatus.

FIG. 4 shows an embodiment of a base layer roller configured for embossing.

FIG. 5 is an illustration of an embossing roller with a dot pattern.

FIG. 6 schematically shows an embossing system with an upper nozzle of hydraulic punching and which includes hydraulic punching jets above.

30 FIG. 7 schematically shows an embossing system with a bar of the lower nozzle of hydraulic punching and which includes hydraulic punching jets above.

FIGS. 8-10 are photographs that show embossed nonwoven materials.

Detailed description

An embossed nonwoven material of improved thickness, softness and / or broth is obtained using the processing methods described herein. You can also obtain nonwoven materials with a different surface embossing.

A preferred nonwoven material according to the present invention comprises a thermoplastic web of continuous filaments and short fibers integrated in and lining the thermoplastic web. The nonwoven materials produced by the methods described herein are double-sided products. The non-woven material receives embossing due to the movement of the short fibers and continuous filaments by a set of water punching jets that push the fibers towards the embossed support, and by the reflection of the water, since it is repelled out of the support embossing

Another preferred nonwoven material according to the present invention comprises a veil of cut fibers.

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hydro-interlaced and short fibers integrated in and covering the veil of interwoven cut fibers. The nonwoven materials produced by the methods described herein are double-sided products. The non-woven material experiences embossing due to the movement of short fibers and cut fibers entwined by a set of hydraulic punching jets that push the fibers towards the embossing support, and by water reflection, as it is reflected outside the support of embossing

Still another nonwoven material according to the present invention comprises a first set of short fibers integrated in a veil formed from a second set of short fibers. The second set of short fibers has an average fiber length of at least twice the average length of the fibers of the first fiber set. The non-woven material undergoes embossing due to the movement of the short fibers and the cut fibers interwoven by a set of hydraulic punching jets that push the fibers towards the embossing support, and by the reflection of the water, since it bounces off the support embossing The nonwoven materials produced by the methods described herein are double-sided products.

The embossing process is useful with nonwoven materials that have base weights of about 7 gmc to about 300 gmc.

Some suitable composite nonwovens are described in U.S. Patent Application No. 10 / 169,682. More particularly, the filaments generally comprise artificial filaments, in particular substantially continuous filaments, and can also be naturally occurring filaments. Synthetic filaments are typically made of a thermoplastic material, for example a polyamide, polyurethane, polyester, polylactic acid (APL), or polyolefin, or a copolymer, for example block copolymer, containing monomeric olefin units. The filaments may also comprise, or consist of, a double component or a double constituent or mixed filaments or fibers. Suitable thermoplastic filament materials are described in US-A-5 151 320 and US-A-5 573 841. Artificial cellulosic fibers, such as viscose rayon or liocel fibers, can also be considered.

If long fibers are used, they will typically be synthetic fibers formed from the materials used to make substantially continuous filaments, or fibers of natural origin, including, but not limited to, wool and / or cellulose fibers such as cotton.

Composite nonwoven materials comprising a veil of hydro-interwoven cut fibers and short fibers integrated in and coating the veil of interwoven cut fibers are described in US Patent No. 3,485,706. Mixtures of filaments or fibers of different materials can be used, for example, different thermoplastic materials. In addition, the presence of other components, which do not interfere, is not excluded.

Short fibers can be synthetic or can be derived from a wide range of natural sources of cellulose fibers, such as wood pulp fibers (including hardwood pulp, softwood pulp and mixtures thereof), although they also enter Consideration of non-wood vegetable pulp fibers such as those derived from cotton, linen, sisal, hemp, jute, esparto, bagasse, straw and abaca fibers. Mixtures of different cellulose pulp fibers can also be used. Mixtures of cellulose fibers and artificial fibers also come into consideration. Cellulose pulp fibers, which can be used, include conventional papermaking fibers, in particular having a fiber length of 6 mm or less. The average fiber length is typically greater than 0.7 mm and is usually about 1.5 to 5 mm. Conventional papermaking fibers include wood pulp fibers produced either by chemical digestion of the wood (the well-known Kraft process), or by mechanical decay, or by a combination of the two methods mentioned above (i.e., CTMP , chemo-thermo-mechanical pulp). Short fibers may also comprise synthetic fibers or other artificial fibers, for example in an amount of up to 50 percent by weight of the total fiber content of the veil containing cellulose fiber based on economic considerations. Synthetic or artificial fibers can be added in larger quantities to achieve other desired properties. Such artificial fibers include, for example, fibers made of cellulose, polyester, polylactic acid (PLA), polyolefin (for example, polyethylene or polypropylene), polyamide (for example, a nylon), rayon, liocel or the like. Suitable artificial fibers include those having a fiber length from about 0.7 to 25 mm and a denier per filament of about 1.0 to about 6.0 (0.11 to 0.67 tex).

A third preferred embossed nonwoven material according to the present invention can also be produced by applying the reflective embossing technique to a paper laid in wet or nonwoven web. The wet-laid veil can comprise from a single layer consisting of pulp fibers for papermaking (one or more types), and, optionally, a percentage of artificial short fibers (0.7 to 25 mm in length). The wetted veil can also comprise two or more layers, each layer consisting of pulp fibers for papermaking (one or more types), and, optionally, a percentage of artificial short fibers (0.7 to 25 mm in length). In multi-layered veils, the type and percentage of fibers in each layer may be the same, or they may be different from the other layer (s). In multi-layer veils, the base weight of each layer can be the same or

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It may be different from the other layer (s).

For simplicity, reference will be made to an embodiment of a non-woven composite material embossed in reflective form comprising a plurality of short coating fibers and hydraulically punched in a nonwoven web comprising substantially continuous thermoplastic filaments. However, it should be understood that this description also encompasses other double-face embossed nonwoven materials.

The fiber denier is chosen independently for each portion of the embossed nonwoven composite. The fiber denier for the substantially continuous thermoplastic filaments will be in the range of about 0.1 to about 45 conveniently in the range of about 0.5 to about 30 and typically in the range of about 0.8 to about 10. The nonwoven web comprising filaments Substantially continuous thermoplastics will have a basis weight in the range of about 5 gmc to about 100 gmc and a convenient base weight in the range of about 8 gmc to about 80 gmc and a typical base weight in the range of about 10 gmc to about 70 gmc .

Useful short fibers in the embossed composite nonwoven material in reflective form include cellulose fibers, such as wood pulp and synthetic fibers. The nonwoven web comprising substantially short fibers used in the embossed composite nonwoven material in reflective form will generally have a basis weight of from about 5 gmc to about 100 gmc, conveniently from about 10 gmc to about 80 gmc and typically about from 20 gmc to approximately 60 gmc. Often, short fibers have lengths in the range of 0.7 mm to 25 mm, or 1 mm to 12 mm or 2 mm to 6 mm.

Advantageously, the short fibers are totally, or substantially totally, cellulose fibers. Cellulose fibers can be derived from a wide range of natural sources of cellulose fibers, and are advantageously wood pulp fibers (including wood pulp, softwood pulp and mixtures thereof), although non-woody plant fibers such as those derived from cotton, linen, sisal, hemp, jute, esparto, bagasse, straw and abaca fibers can also be considered. Mixtures of different cellulose fibers can also be used.

Cellulose pulp fibers, which can be used, include conventional short papermaking fibers, in particular having a fiber length of about 0.7 mm to about 6 mm. The average fiber length is advantageously from about 1.5 mm to about 5 mm.

The nonwoven material may optionally contain one or more independently selected processing additives, including, for example, dye pigments, opacifying pigments, functional additives, such as hydrophilic agents, antistatic agents and mixtures thereof. The cross-sectional shape of the aforementioned fibers is typically round although they can be of any shape that is convenient to produce for the intended end use, for example, round, trilobed, triangular, dog bone, flat or hollow.

Examples of synthetic fibers include fibers made from cellulose such as rayon and polymers such as polyester, polylactic acid (PLA), polyolefin (for example, polyethylene or polypropylene), polyamide (for example, a nylon). Suitable synthetic fibers include those that have a fiber denier of about 0.1 to about 45, and an advantageous denier of about 0.5 to about 30 and a typical denier in the range of about 0.8 to about 10.

Typically substantially continuous filaments are extruded, for example by spinning the yarn or spinning in the molten state. Extruded filaments are formed in a conventional manner. Advantageously, the filaments are deposited on a surface that is formed in motion to form a spun veiled filament that extends substantially continuously in the direction of movement (machine).

If the veil is made using long fibers or short fibers that are at least twice as long as the fibers on the side of the short fiber, the two sets of fibers are typically combined by hydraulic punching.

When continuous filaments are used, short fibers are applied to the spun yarn, usually as a layer. The short fibers can be applied to the spun web as a veil or preformed fabric, or they can be formed on the existing base sheet, for example by means of a wet deposition process or by air deposition. The methods by which cellulose fibers can be applied to a base veil material are described in U.S. Patent Nos. 5,151,320 and 5,573,841.

After applying the layer of short fibers to the spun yarn, the two layers are integrated, for example, by pressing or calendering the composite material or by interlacing the cellulose fibers in the veil

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spun yarn Advantageously, the spun tended / short fiber composite veil is subjected to a hydraulic punching operation to form a nonwoven sheet. Hydraulic punching operations are described in US Patents 4,883,709 and 5,009,747. The hydraulic punching operation is preferably carried out by passing the spun yarn / short fiber composite veil under a series of hydraulic punching nozzles that produce a plurality of streams or jets of fluid such that the fluid streams impact the surface above that contains short fiber of the composite material with sufficient force to cause a proportion of the short fibers to be pushed in and combined with the spun filaments. The fluid jets are preferably jets of an aqueous liquid.

The total energy input provided by the fluid jets can be calculated using the formula.

E = 0.125 YPG / bS

where Y = the number of holes per linear inch of nozzle width, P = pressure in psig (pounds per square inch gauge) (1 psi = 0.06895 bar) of liquid in the nozzle, G = volumetric flow in cubic feet per minute (1 pcm = 0.028 m3 / min) per hole, S = the speed of the composite sheet under the jets of fluid in feet per minute (0.305 m / min) and b = the base weight of the resulting sheet produced from hydraulically punched compound in ounces per square yard (1 oyc = 33.9 gmc). The total amount of energy, E, spent on the treatment of the composite sheet is the sum of the individual energy values for each pass under each nozzle, if there is more than one nozzle and / or if there is more than one pass. In general, the total energy input is 0.07 to 0.4 horsepower-hours per pound (HPh / lb) (0.41 to 2.37 MJ / kg). Preferably, however, the total energy input is 0.1 to 0.3 HPh / lb (0.59 to 1.78 MJ / kg), more preferably 0.12 to 0.28 HPh / lb (0.71 to 1.66 MJ / kg). The hydraulically punched composite material can be partially or totally dried using conventional drying processes. The hydraulically punched composite material is a double-face product with one side predominantly substantially comprising continuous thermoplastic filaments and the other side comprising predominantly short fibers.

In order to embossing the nonwoven web reflectively, the hydraulically punched composite material passes between fluid streams of one or more hydraulic punch nozzles and a support. The nonwoven sheet may be dry or wet before embossing takes place. The support has a pattern engraved or embedded in the support surface. The support can be, for example, a belt or a roller as illustrated in Figures 1 to 5. The support is advantageously substantially non-porous and does not drain, so that any fluid that hits the support is reflected outside the support and it goes back to the opposite side of the composite material.

Figure 1 shows a roller assembly 10 according to a first preferred embodiment of the present invention. The assembly 10 includes an embossed roller 20 having a plurality of recesses 22 on the outer surface thereof, and a hydraulic punching nozzle 24. The embossing roller 20 includes a solid or hollow inner cylindrical core 12, an intermediate layer 14 and a outer layer 16 having a plurality of openings 18 formed therein. A liquid is unable to pass through the openings 18, due to the presence of the intermediate impermeable layer 14. The openings 18 of the outer layer 16 in combination with the underlying rubber layer 14 form the plurality of recesses 22 on the surface exterior of the embossed roller 20. The combination of the impermeable layer 14 and the outer layer provided with openings 16 together form a surface with a plurality of shallow recesses.

A hydraulic punching nozzle 24 that produces a plurality of fine jets of fluid 26 is disposed above the embossed roller 20. A segment of non-woven material 30 (wet or dry) passes over the top of the embossed roller 20. The assembly of the roller is configured to receive sheets or rolls of non-woven material 30 between the embossed roller 20 and the hydraulic punching nozzle 24. The roller 20 rotates with a certain circumferential speed. The nonwoven web passes over roller 20 with a linear speed approximately equal to the circumferential speed of the roller, and in the same direction. If desired, the circumferential speed of the roller can be varied in the range of -20% to + 20% with respect to the linear velocity of the nonwoven web. The hydraulic punching nozzle 24 projects jets of punching 26 of water or other suitable liquid into the non-woven material 30, resulting in embossing of at least the bottom surface 32 of the material 30. Depending on the depth and shape of the recesses 22, the pressure of the water punching jets projected from the hydraulic punching nozzles 26, and the base weight and composition of the nonwoven material, the embossing may also be visible on the upper surface 34 of the non-material fabric 30.

Figure 2 shows a roller assembly 110 that is similar to that of Fig. 1, except that the hydraulic punching nozzle 124 is located below the embossed roller 118 and the hydraulic punching nozzle 124 projects jet jets 126 of injector liquid upwards, towards the lower surface 132 of the non-woven material 130, resulting in embossing of at least the upper surface 134 of the material 130. Depending on the depth and shape of the recesses on the surface of the roller 118, the pressure of the water punching jets of the hydraulic punching nozzles 126, and the base weight and composition of the

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non-woven material, the embossing can also be visible on the lower surface 132 of the non-woven material 130. The roller 118 rotates with a certain circumferential speed. The nonwoven web passes the roller assembly with a linear speed approximately equal to the circumferential speed of the roller, and in the same direction. If desired, the circumferential speed of the roller can be varied in the range of -20% to + 20% with respect to the linear velocity of the nonwoven web.

Figure 3 shows a roller assembly 210 with three hydraulic punching nozzles 224, 225 and 227. A first upper hydraulic punching nozzle 224 is disposed above the embossed roller 218. A lower hydraulic punching nozzle 227 is disposed below the embossed roller 218, and a second upper hydraulic punching nozzle 225 is disposed next to the first upper hydraulic punching nozzle 224. The hydraulic punching nozzle 224 and 225 can each be used alone, or they can be used simultaneously. The hydraulic punching nozzle 227 can be used in combination with the hydraulic punching nozzle 224 and / or the hydraulic punching nozzle 225 if additional hydraulic jet treatment is desired. The speed of rotation of the roller with respect to the linear speed of the nonwoven material is maintained in the range of -20% to + 20%, as mentioned above.

Figure 4 shows an embossed roller 260 having alternating transverse recessed flanges 262 and rows 264 of small circular recesses. Figure 5 shows an embossing roller 270 with an embossing of points on its outer surface. It is noted that the rollers can either be constructed with an outer layer that has openings that, together with an underlying layer form recesses, or can be constructed with an outer layer that has recesses formed on its outer surface. When the outer layer has recesses formed therein, it is advantageous but not necessary to form the metal support. The support has a plurality of recessed areas engraved therein. The embossed roller can be either solid or a hollow shell. Useful patterns in the support are not known to be limited and can be chosen to provide the desired fluid reflection capacity and aesthetic characteristics for the embossed nonwoven material in reflective form.

Fig. 6 illustrates an embossing system 300 in which the hydraulic punching equipment is placed immediately after an embossing roller 320. In this system, the nonwoven material generally moves in the direction shown by the arrow D. A substantially continuous filament sheet and combined with short fibers. The short fibers can be deposited on the filament sheet, or they can be applied as a preformed veil that combines with the continuous filament veil to form a preliminary sheet 325. The preliminary sheet 325 is subjected to a water jet process for forming a hydraulically punched nonwoven web 330 in the form of a sheet using a set of injector jets from the hydraulic punching nozzles 365, 366 and 367, as shown in Fig. 6. Vacuum boxes 380, 381 and 382 are used below the hydraulic punching nozzles 365, 366 and 367, respectively. The hydraulically punched nonwoven web 330 is then passed over an embossed roller 320 and is brought into contact with the fluid of a hydraulic punching nozzle 324 which produces a plurality of water punching jets (not shown). Vacuum boxes 390 and 391 are used after roller 320 in order to remove excess fluid. The hydraulically punched and embossed veil is then dried. The surface of the bottom material 332, which is rich in continuous filaments, is next to the roller 320.

The embossing system 400 shown in Fig. 7 is similar to that of Fig. 6 except that the hydraulic punching nozzle 424 for embossing the nonwoven material is placed under the embossing roller 420 and therefore the surface of the veil is not fabric that is closer to the embossed roller 420 is the upper surface 434 which is rich in short fibers.

In the embodiments described above, the hydraulic punching nozzles are positioned in front of the support so that the fluid ejected by the hydraulic punching nozzles is directed through one side of the nonwoven material so that it hits the embossed support. The position of the hydraulic punching nozzle with respect to the support is not critical and the hydraulic punching nozzles can be mounted in any position with respect to the support as allowed by the equipment available and required to achieve a desired energy input. The embossing process uses high pressure fluid to provide a high energy input to the hydraulically punched composite.

In most cases, the incident fluid is reflected from the embossed support and directed again to the opposite side of the hydraulically punched composite. In some preferred, no negative pressure (vacuum) is applied to the hydraulically punched composite material during the reflective embossing process so that the amount of fluid that is reflected outside the support and on the opposite side of the hydraulically punched composite material can be maximized. The use of a non-draining and / or non-porous support is advantageous to maximize the reflection of the fluid outside the support and on the opposite side of the hydraulically punched composite. A reflective embossing process moves the short fibers and substantially continuous filaments both when the reflective embossing hydraulic punching nozzles initially impact the composite material and when the fluid is reflected outside the embossing support.

The embossed nonwoven composite material is dried using conventional drying processes.

The embossed nonwoven composite material in reflective form may have a visual and tactile appearance ranging from embossing in the form of images of opaque and / or translucent regions with little or no tactile texture to a fully textured surface depending on the embossing of the support and hydraulic energy imparted by the hydraulic punching nozzle. The embossed nonwoven composite material may become softer than the hydraulically punched precursor composite material. The material may be thicker than the hydraulically punched precursor material. For example, the thickness can be increased by at least 5%, at least 10%, or more. In this context, the term susceptibility to draping indicates a relative softness. In some cases, the embossed nonwoven composite material is more susceptible to draping than the hydraulically punched precursor composite. For example, the susceptibility to draping can be improved by 50% or more, or 10 100% or more. The embossed nonwoven composite material in reflective form may have a different embossing. How I know

I mentioned earlier, embossing can be a visual image of opaque and translucent regions and / or be a textured surface.

The following examples are included for purposes of illustration so that the description can be more easily understood and in no way intended to limit the scope of the description unless specifically indicated otherwise.

Examples 1-3 and A

Hydraulically punched composite material A was used as a precursor material for samples 1 to 3. Hydraulically punched composite material A comprised a mixture of short fibers of 85% pulp fiber and 15% thermoplastic, two component direct access fiber that was hydraulically punched in a veil of 20 substantially continuous thermoplastic filaments. The hydraulically punched nonwoven compound had a basis weight of approximately 56 gmc. The short fiber mixture consisted of 42 gmc and the filaments consisted of 14 gmc. The hydraulically punched composite was a double-sided product with one side consisting predominantly of all substantially continuous thermoplastic filaments and the other side consisting predominantly of all short fibers. The hydraulically punched composite material A before the reflective embossing had the properties illustrated in Table 2.

A conventional base layer cylindrical roller 12, shown in Figure 1, was wrapped with a perforated aluminum cylindrical sheet 16 to provide a support 1-20 with a lowered embossing defined by the recesses 22. In the initial tests, it was It is possible to add a rubber sheet 14 between the base layer roller 12 and the perforated aluminum sheet 16. Two embossments were evaluated; a Windsor pattern, shown in Figure 4, and a dot embossing, comprising a series of openings of approximately 3 mm spaced approximately 1.5 mm.

A single hydraulic punching nozzle 24 that produces a plurality of water punching jets 26 is mounted right next to the position of the upper center dead center of the base layer roller. The tests were performed using a water pressure of 1100 psi (76 bar).

The sample 1 was made by coating the side of substantially continuous filaments of material A, that is, the bottom surface 32 shown in Fig. 1 towards the embossed support. Sample 2 was made by coating the short fiber side of cellulose rich in pulp of material A towards the embossed support. Sample 3 used the same base layer roller and perforated aluminum sheet of Samples 1 and 2, but disposing a rubber sheet 14 between the base layer roller 12 and the perforated aluminum sheet 16. The process conditions and the properties can be found in Tables 1 and 2.

 Table 1

 Sample

 Embossing Embossing Reinforcement Comments

 one

 points none half the side of the filament towards the embossed support, the side of the fiber cuts towards the hydraulic punching nozzle

 2

 points none good the side of the short fibers towards the embossed support, the side of the filament fiber towards the hydraulic punching nozzle

 3

 Poor rubber points waterproof mortar deep on the side of the roller, embossed destroyed

Samples 1 to 3 were run at a linear speed of 25 meters / min with a pressure of the hydraulic punching nozzle of 1100 psi (76 bar), and using 90-diameter diameter jet holes, and a gap of approximately 6 mm between the hydraulic punching nozzle and the base layer roller.

No negative pressure (vacuum) was used in any of samples 1 to 3.

 Table 2

 Property

 Units Sample A Sample 1 Sample 2

 Base weight

 gmc 57 59 60

 Dry thickness

 microns 540 539 564

 Wet thickness

 microns 447 499 528.5

 % Increase in wet thickness

   12% 18%

 Fabric Touch Meter (HOM)

 MD

 grams 52.4 34.1 24.5

 CD

 grams 25.5 13.1 8.9

 Improved Draping

   165% 233%

 Martindale abrasion resistance

 Revolutions (average) 15.5 9.5 15.5

5

As shown in Table 2, the wet thickness of the embossed samples, Samples 1 and 2, was greater than that of the control, Sample A.

The fabric touch measuring instrument (HoM) is available through Thwing-Albert Instrument Co. The one-touch touch meter (HoM) measures the force (in grams) required to push a fabric into an opening of groove. High values of applied force indicate a rigid, non-flexible test sample, and on the contrary lower force values indicate softer and more flexible test samples. Draping is a descriptive term that indicates the relative softness of the tissue. A test on the fabric touch meter in a soft test sample that can be draped will result in a low measured force. Draping is generally measured by testing both in the machine direction (MD) and in the transverse direction (CD). The tests with the fabric touch meter were carried out in accordance with the TAPPI test method, T498.

The improvement of the draping of the samples was calculated by the following method:

Drape improvement (%) = (HoMmd, original + HoMcd, original) x 100

(HoMmD, embossing + HoMcd, embossing)

It has been theorized that sample 2 speaks an improved thickness and draping compared to sample 1, due to the ease of movement of the short fibers facing the embossed waterproof support compared to the continuous filaments facing the waterproof support embossing

Examples 4-20

A series of examples were made in which a substantially continuous filament sheet was obtained and

I combine with short fibers in an interlacing process to form a hydraulic punching sheet using the system shown in Figs. 6 and 7. Vacuum boxes were used below the three hydraulic punching nozzles used for hydraulic punching. The first series of examples, for which the data are shown in Table 3, used a nonwoven material containing 70% by weight of short pulp fibers 5 and 30% by weight of continuous fibers. The second series of examples, for which the data is shown in Table 4, used a nonwoven material containing 70% by weight of short fibers, of which 4/5 by weight were pulp fibers and 1/5 in Weight were polyester fibers. The third series of examples, for which the data is shown in Table 5, contains 70% by weight of short fibers and 30% by weight of continuous fibers. The following parameters were used:

10 The trials were run at 30 - 35 feet / min (0.15 - 0.18 m / s)

The majority of the tests were performed with a hydraulic punching pressure of 1000-1100 psi (69-76 bar) to combine the short fiber layer with the continuous filament veil. Water was used as the fluid.

In the embossing stage, the pressures of the hydraulic punching nozzle varied from 300 to 1000 psi (21-69 bar). Water was used as the fluid.

15 In some cases, the material was on the embossing roller and in other cases, the material was under the embossing roller. In the data in the Tables, Route A corresponds to Fig. 6 and Route B corresponds to Fig. 7.

The resulting sheets were analyzed for thickness, embossing / texture and fabric touch meter readings.

Table 3

 Material Description:

   Pulp / continuous filament

 Sample ID:

   Sample 4 Sample 5 Sample 6- 2 Hydraulic punching nozzles Sample 7-300 Sample 8 -400 Sample 9-500

 Pressure of the hydraulic punching nozzle # 1 - 3

 psi / bar 1000 / 68.9 1000 / 68.9 1000 / 68.9 1000 / 68.9 1000 / 68.9 1000 / 68.9

 Punching pressure

 psi / bar - 1000 / 68.9 1000 / 68.9; 1000 / 68.9 300 / 20.7 400 / 27.6 500 / 34.5

 Route A Route A Route B Route B Route B was not used

 Side facing embossing

 CTF CTF Pulp Pulp Pulp

 Base weight

 g / m2 64 63 64.5 65 61 63

 Thick-Dry

 microns 540 611 645 574 614 688

 Dry Thickness Increase

     13% 19% 6% 14% 27%

 Thickness - wet

 microns 485 545 581 546 572 563

 Increase in wet thickness

     12% 20% 13% 18% 16%

 Fabric touch meter - MD

 g 56.35 64 82.07 8 61.05

 Fabric touch meter - CD

 g 16.25 15.32 14.27 13.72 12.52

 Texture & Embossing Range *

 Dry 1 1 1.5 1 2 3

 Damp

 1 1 1 1 2 3

CTF - continuous filament

* Values from 1 to 4 for the texture / embossing range indicate poor, reasonable, good and excellent, respectively.

Table 4

 Material description:

   Pulp / PET fiber 6 mm 1.5 dpf / continuous filament

 Sample ID:

   Sample 10 Sample 11-300 Sample 12-1000 Sample 13-300 Sample 14-500

 Pressure of the hydraulic punching nozzle # 1 - 3

 psi / bar 1000 / 68.9 1000 / 68.9 1000 / 68.9 1000 / 68.9 1000 / 68.9

 Punching pressure

 psi / bar - 300 / 20.7 1000 / 68.9 300 / 20.7 500 / 34.5

 Route A Route A Route B Route B was not used

 Side facing the embossing roller

 CTF CTF Pulp Pulp

 Base weight

 gmc 56 55 55 55 55

 Thick-Dry

 microns 544 490 574 544 650

 Dry Thickness Increase

   -10% 6% 0% 20%

 Thickness - wet

 microns 496 450 541 487 550

 Increase in wet thickness

   -9% 9% -2% 11%

 Fabric touch meter - MD

 g 18.4 26.7 30.0 23.0 30.9

 Fabric touch meter - CD

 g 6.8 7.9 8.0 9.8 11.5

 Texture & Embossing Range *

 Dry 1 1 1 2 4

 Damp

 1 1 1 1 3

 CTF - continuous filament

Table 5

 Material description:

   Pulp / continuous filament

 ID number:

   Sample 15 Sample 16-300 Sample 17-1000 Sample 18-300 Sample 19-400 Sample 20-500

 Pressure of the hydraulic punching nozzle # 1 - 3

 psi / bar 1000 / 68.9 1000 / 68.9 1000 / 68.9 1000 / 68.9 1000 / 68.9 1000 / 68.9

 Punching pressure

 psi / bar - 300 / 20.7 1000 / 68.9 300 / 20.7 400 / 27.6 500 / 34.5

 Route A Route A Route B Route B Route B was not used

 Side facing the embossing roller

 CTF CTF Pulp Pulp Pulp

 Base weight

 g / m2 67.29 66.5 68 63 71 68

 Thick-Dry

 microns 467 528 645 607 652 693

 Dry Thickness Increase

   13% 38% 30% 40% 48%

 Thickness - wet

 microns 442 460 586 520 594 606

 Increase in wet thickness

   4% 33% 18% 34% 37%

 Fabric touch meter - MD

 g 114.5 116 74 108 132 117

 Fabric touch meter - CD

 g 18 20 21 17 20 12

 Texture & Embossing Range

 Dry 1 2 2 1 2 3

 Damp

 1 1 1.5 1.5 2 4

 CTF - continuous filament

On route B, the maximum pressure of the hydraulic punching nozzle on the hydro-roll roller was 500 psi (35 bar). Pressures above 500 psi (35 bar), would cause the pulp removal of the compound from

5 pulp / continuous filament. While in the previous trial where there was a softening effect in addition to the

embossed, this softening effect was no longer observed with this single stage process. However, significant increases in thickness were measured in the hydro-embossed samples that were embossed using route A and route B. Route B that centered the pulp-rich face toward the recessed roller produced an embossing with raised dots / bumps. A significantly textured surface can be observed and felt. Route A, which centered the rich side 10 in continuous filament towards the recessed roller, produced an embossing similar to that of a watermark. Could

observed a textured surface, but it didn't feel.

Figs. 8-10 are photographs that show some of the dry embossed samples. Figure 8 shows sample 14 at the top and sample 12 below. It is observed that the embossing in sample 14, which was made using route B, is more pronounced than embossing in sample 12, which was made using route A. This 15 occurred despite the fact that greater pressure was used on Hydraulic punching during the sample embossing process 12 that was employed in the fabrication of the sample 14. When the short fiber side of the double-woven non-woven sample was oriented toward the embossed roller, the free ends of the fibers Short allowed short fibers to move in order to form the embossed surface. On the other hand, when the substantially continuous filaments were oriented towards the embossed roller, there was less movement of the filaments and therefore it is

less visible an embossing. The same effect is shown in Fig. 10, in which the sample at the top is sample 9 to 500 psi (34.5 bar) (route B) and the sample at the bottom, is sample 5, at 1,000 psi (68.9 bar) (route A). Fig. 9 shows sample 20 at the top and sample 17 at the bottom. It is noted that low pressure embossing (300 psi / 20.7 bar) of sample 17 using route A resulted in a less pronounced embossing than higher pressure embossing of sample 20 using route B.

Claims (9)

5 10 fifteen twenty 25 1. A double-sided, non-woven fibrous material comprising a first set of hydraulically punched fibers with a veil of a second set of fibers, the first set of fibers mainly containing short fibers having a length of 0.7 mm to 25 mm and the second set of fibers containing mainly one of (a) substantially continuous filaments, and (b) short fibers having an average fiber length of at least twice the average fiber length of the first set of fibers, having the material a first surface predominantly comprising the first set of fibers and a second opposite surface predominantly comprising the second set of fibers, the first surface being embossed in a reflective form to have a visual and tactile appearance depending on a embossing support in which embossing is performed. 2. The material of claim 1, wherein the fiber in the first set has lengths in the range of 0.7 mm to 12 mm. 3. The material of claim 1, wherein at least 90% by weight of the fibers in the second set are substantially continuous filaments; 4. The material of claim 1, wherein at least 90% by weight of the fibers in the second set are short fibers. 5. The material of claim 1, wherein the second surface of the composite material has portions that have been directly impacted by a fluid stream and the first surface has portions that have been impacted by a reflected fluid stream. 6. The material of claim 1, wherein the short fibers in the first set comprise cellulose fibers. 7. The material of claim 1, wherein the short fibers in the first set comprise a mixture of cellulose fibers and artificial fibers. 8. The material of claim 1, wherein the second set of fibers mainly contains substantially continuous filaments formed from at least one of polyester, polyamide, polyurethane, polylactic acid and polyolefin. 9. A cleaning substrate comprising the nonwoven material of claim 1.